Method of knitting pile fabric



Sept 15, 1959 Filed June 11, 1956 B. STEVENS, JR 2,903,869

METHOD OF KNITTING PILE FABRIC 2 Sheets-Sheet l m 3 FIG. 4

INVENTOR.

Brooks Srevens, Jr.

J A-MW.

ATTORNEY P 1959 v B. STEVENS, JR 2,903,869

METHOD OF KNITTING FILE FABRIC Filed June 11, 1956 2 Sheets-Sheet 2mmvron Brooks Stevens, Jr.

ATTQRNEY States Patent 90% METHOD or KNITTING 'PILE FABRIC l mon-StevensJ Ce so a a r s Textile, G nerat ve, h l e a eerperefien App i tion Junemime-seria N 0, 9 c1. bee-92 surface d to a method of knitting suchimproved fabric. P' rics, such as terry cloth, toweling etc. can be knitas a, yariation of plain jersey fabric, using two yai ns Qne formsthe'pile loops, which may'later severed,if desired, and the other formsthe body a ab ie- 1 1 t is ea e. e P e f i is h' using latch cylinderneedles cooperable with pile forming elements sl ab e i heeyes eentainin a dia mounted I 2 nee l Qih'fler V i W il 9f knitting a pile fabricon a jersey 'alehihe s' e'ii 'e eh e he es cooper-able sinkers mountedin an d1 the needles sinkers being cooperatively r li le whichjrnay havepattern wheels associated therewith. The sinkersare formed with nosesand throats, and the needles draw the pile loop forming ram e e: th ho e0f the ha s to f rm the p 19 r 7 Th y s it h at b tan in ra is fed to hn below the sinke e es a d a the level of t th eats,

In'another method, an inside dial is equipped with needles, and thecylinder needles draw the pile yarn down between the dial nestle te erthe loops, the t h @Y a hib s n ked, 1 12 y t e e hd below 1" of dia lneedles, In a variation of this the dia ne dle a erl e l k mounted ,einside dish e ii ai h he n e o h s to s as lea hat his he h n f means tou awesome th di l ne dl at The ahries. made by h se tw m h e identicalresp'ect'tosti tch formation and the arrangement of the twoyar -nsin'the stitch. However, they'frequently char'actcriz d by a very rough,irregular, and un- I or' ersey side. a result of the fact tha faeh P e00p aftefi me i n. us e freed m 4 ming means, such as the sinkers,needles, a b anks, hen ethle new s is formed by a subsequent yarn feed.o I Quringsuch subsequent yarn feed, the new stitch, comnes d ot th pi e9. 2 am an s e 9? b Y i '1 b the need hou h he t t h rm d during t e nutee The s i hl y n orm lly a o a hut .thexloop yarn does have a greatdeal of slack or loosen ssd e t r ease f. t ap fro e d e ment The ietehe tf e r f e eed and yarns of the new stitch being drawn through thepreviously formed stitch may pull some of the loop yarn slack through tothe. ac e, of the fabri n an irregu ar manner, thus causing the fabricback to have an unsightly appearance.

As stated, in both described methods, the hook of the cylinder. needlefirst catches the loop yarn and later the stitch yarn. During the nextyarn feeding operation, the n d stitch ya m y chan e he r el ive p i iehon the needles, so that either the relatively tight stitch 2,903,869Patented Sept. 15, 1959 yarn or the relatively loose loop yarn appearson the back of the fabric. k

In accordance with the invention, a pile knit fabric having a smoothback or jersey surface is produced by reversing the positions of theloop and stitch yarns so that the cylinder needles catch the stitch yarnfirst and the loop or pile yarn subsequently.

In one method of effecting the invention, the dial is equipped withneedles which draw long loops of the pile yarn through the cylinderneedles after the latter have first caught the stitch yarn. During thesubsequent feed, there is no tendency for the two yarns to shift theirrelative positions. The long loop yarn appears on the jersey side of thefabric in a. larger and looser stitch covering the tighter stitch yarn,resulting in the jersey side having a soft surface and smooth appearancedue to the lack of tension in the surface yarn.

For an understanding of the invention principles, reference is made tothe following description of a typical embodiment thereof as illustratedin the accompanying drawing. In the drawing:

Fig. 1 is a somewhat diagrammatic perspective view illustrating theprior art knitting of pile fabric on a machine equipped with latchcylinder needles and sinkers mounted in an outside dial;

Figs. 2, 3 and 4 are diagrammatic elevation views i1- lu stratingsuccessive steps of the pnior art method of knitting pile fabric usingcooperating cylinder and dial needles;

Fig. 5 is a partial elevation view of a cylinder needle of Figs. 2, 3and 4, illustrating the relative positions of the pile and stitch yarnsin the hook end of the needle;

Figs. '6, 7 and 8 are diagrammatic elevation views, respectivelycorresponding to Figs. 2, 3, and 4, illustrating successive steps of theinvention method of knitting pile fabric; and

Fig. 9 is a view, similar to Fig. 5, illustrating the positions of thepile and stitch yarns in the needle when using the invention method; I

Fig. 10 is a developed plane view of the dial needles and their cams inrelation to a developed elevation view of the cylinder needles and theircams rotated into the plane of the dial needles and cams.

Referring to Fig. 1, a pile fabric 10 is illustrated as being knit usinglatch cylinder needles and sinkers 20. In this method of knitting pilefabric, needles 15 are successively elevated to the knit position, aboveupper noses 21 of sinkers 20, to catch loop pile yarn 25 fed at the knitposition or level. Needles 15 may be selectively raised as shown by theusual cam and jack-pattern wheel arrangements common in the art, oralternatively all cylinder needles may be raised. Similarly, sinkers areoperated by the usual sinker cams and associated jackpattern wheels sothat alternate sinkers 20B and 20D are projected further thanintermediate sinkers 20A and 20C. However, if all needles are raised totake yarn, then all the sinkers will be projected in the same manner assinkers 20B and 20D.

As loop pile yarn is caught in the hooks 16 of needles 15, it is pulleddownwardly as the needles 15 are retracted toward the cast-off positionto form loops over the lower noses or surfaces 22 of the alternatesinkers and over the upper noses of the intermediate sinkers as shown,or alternatively on the noses of all the sinkers. Stitch or body yarn isfed to needles 15 at the level of the throats 23 of sinkers 20, so thatstitch yam loops are drawn over surfaces 23. It will be noted that thedouble yarn new stitches 11 are drawn through previously formed stitches12 by needles 20, the loops engaged with noses 22 forming pile loops 13in fabric 10 as they slip off sinkers 20 when the latter are retracted.

Figs. 2 through 5 illustrate a known method of knitting pile fabricusing latch cylinder needles 15 cooperating with latch dial needles 35operated by cams and jackpattern wheels in a known manner. In thismethod, cylinder needles 15 are raised to the knit position to catchpile yarn 25 which is fed at this level. As pile yarn 25 is drawn downto the level of dial needles 35, the pile yarn is caught by the dialneedles to pull the pile loops 13 inwardly as the pile yarn is pulleddown below needles 35 by needles 15. Stitch yarn 30 is fed at the levelof needles 35 and also pulled down by needles 15. As the stitches andloops are cast off needles 15 and 35, a pile fabric is formed identicalwith that of Fig. 1.

It should be noted that in both the method of Fig. 1 and that of Fig. 2,pile yarn 25 is fed to needles before stitch yarn 30 is fed thereto.Thus, pile yarn 25 is above stitch yarn 30 in hooks 16 of needles 15,and the yarns may retain this position as they are drawn throughpreviously formed stitches 12, 13 which close latch 17 of needle 15.Both of these methods, as previously mentioned, produce a rough,irregular and unsightly back surface on the pile fabric.

In accordance with the present invention, the relative feeding positionsof the two yarns are reversed, so that stitch or body yarn 30 is caughtfirst and pile yarn 25 caught subsequently. One method of effecting thisis to use cooperating cylinder and dial needles, as used in the priorart method shown in Figs. 2-5, although the invention method can bepracticed using cylinder needles cooperating with sinkers.

Figs. 6-10 illustrate the invention method as efiected using cooperatingcylinder and dial needles. Referring to these figures, stitch or bodyyarn 30 is fed to cylinder needles 15 'at the knit level, while pileyarn 25 is fed to extended dial needles 35 at the level of theseneedles. Thus, stitch yarn 30 is caught first by needles 15 and engagesthe top of hooks 16. As cylinder needles .15 pull stitch yarn 30downwardly, dial needles 35 pull pile yam 25 inwardly, so that hooks 1-6of needles 15 catch pile yarn 25 at the level of needles 35. Pile yarn25 thus lies beneath stitch yarn 30 in hooks 16 as loops 13 are pulleddown by needles 15 while yarn 25 is held by needles 35. Dial needles 35may be drawn in before needles 15 move down, if desired. Also, thefabric may be formed bythe cylinder needles pulling the pile yarn overthe dial needles, this amounting to an equivalent reversal of parts andtheir functions.

At the subsequent feed, there is no tendency for yarns 25 and 30 toshift their relative position. Loop yarn 25 appears on the back of thefabric as a longer and looser stitch covering the tighter stitch yarn30. The back has a soft surface, due to the lack of tension in thesurface yarn, and has a very smooth appearance.

Fig. 10 illustrates the sequence of movement of cylinder needles 15 anddial needles 35 during one complete cycle. The needles are assumed tomove from right to left, with lines 32 indicating the cylinder ofmovement of needles 15 and lines 31 indicating the plane of movement ofneedles 35. The cam path for dial needles 35 is shown much closer to theline 32.0f needles 15 than it would be in a practical machine.

At the extreme right of Fig. 10, cylinder needles 15 are shown in theirclear position. As the needles move to the left, they are drawn down bystitch cam 40 to surface 41 of the latter. In this position, the latchesof the cylinder needles are closed but the hooks are still well abovethe sinkers so that yarn will reeve freely through the closed hooks. Cam40 then draws needles 15 down to knock over level 42 where the stitch isformed.

Needles 15 are then raised slightly by surface 43 of cam 45 to relievethe stitches, after which needles 15 ride up surface 44 of cam 45 to thetuck level 46 of this cam.

The needles 15 remain at the tuck level for a short time. after whichthey are raised to the clear or stitch level 47 of cam 45. The needles15 then encounter another stitch cam 40' and the cycle is repeated.

A yarn guide 50 is shown near the left end of Fig. 10 and has eyelets51, 52 which may be located in vertical alignment in accordance with theinvention, body yarn 30 being fed through upper eyelet 51 and loop yarn25 through lower eyelet 52.

Dial needles 35 are moved outwardly by surface 53 of cam 55 so thattheir hooks are beyond cylinder needle line 31 just after cylinderneedles 15 pass the clearing surface 47 of cam 45'. After needles 35pass along surface 54 of cam 55, they are drawn inwardly taking loopyarn 25 in their hooks just before needles 15 reach cam surface 41.Needles 35 continue inwardly to cam surface 56 at which time they havedrawn sufiicient pile or loop yarn 25. Needles 35 preferably reachsurface 56 before needles 15 start to draw the pile yarn through the oldloops as needles 15 reach cast-off surface 42, and dial needles 35 arepreferably moved out slightly to surface 57 as needles 15 ride down tothe cast-off position. This latter movement releases sufficient yarn tothe cylinder needles 15 so that these may draw their stitches.

After leaving surface 57, needles 35 are moved outwardly by surface 58to the clear position at surface 61, and are then retracted alongsurface 62 to the knock-off surface 63 where the needles cast-01f theloop yarn from their hooks. The needles 35 are then moved out along camsurface 64 to the tuck position as they encounter surface 66. l

As needles 35 are moved toward the tuck position, their latches areopened by latch opener before cylinder needles 15 are projected upbetween the dial needles.

While the invention has been illustrated and described as using latchcylinder needles, the 'method may be equally well performed using springcylinder needles, and wherever the term cylinder needle(s) is used inthe specificationand claims it is to be understood'as comprehendingspring needles. p

While a specific embodiment of the invention has been shown anddescribed in detail to illustrate the application of the inventionprinciples, it will be understood that the invention may beembodied-otherwise without departing from such principles. 7 g g What isclaimed is:

1. A method of knitting pile fabric utilizing cylinder needlescooperable with movable, dial needles, said method comprising, in eachstitch forming sequence, feeding a body yarn to the hooks of thecylinder needles in the knit position; substantially simultaneouslytherewith, feeding a pile yarn to the dial needles, operating betweenthe cylinder needles, at a level below the hooks of the cylinder needlesin the knit position; drawing loops of pile yarn transversely betweenpairs of cylinder needles;

subsequently catching the drawn pile yarn in the hooks of the cylinderneedles below the body yarn therein while retaining the pile yarn loopsin drawn position; drawing the body and pile yarn in the needle hooksthrough previously formed loops around the cylinder needles; andsubsequently casting off the newly formed 'body yarn loops and theretained pile yarn loops.

' 2. A method of knitting pile' fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a body yarn to the hooks of the cylinder needles at a levelabove the dial needles; feeding a pile yarn to the dial needles whilethe hooks of the cylinder needles are above the dial needles; drawing aloop of-pile yarn transversely between pairs of cylinder needles as thelatter are moved toward a cast-off position; catching thepile yarn inthe hooks of the cylinder needles below the body yarn therein duringsuch movement toward the east-off position; drawing the body and pileyarn caught in thehooks of the cylinder needles through previouslyformed loops WW the cylinder needles; and subsequently casting ofi thenewly formed loops from the cylinder needles and the pile yarn loopsfrom the dial needles.

3. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a body yarn to the hooks of the cylinder needles at a levelabove the dial needles; feeding a pile yarn to the dial needles whilethe hooks of the cylinder needles are above the dial needles; drawing anelongated loop of pile yarn transversely between pairs of cylinderneedles as the latter are moved toward a cast-off position; catching thepile yarn in the hooks of the cylinder needles below the body yamtherein during such movement toward the cast-01f position; drawing thebody and pile yarn caught in the hooks of the cylinder needles throughpreviously formed loops around the cylinder needles; and subsequentlycasting oif the newly formed loops from the cylinder needles and thepile yarn loops from the dial needles.

4. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a body yarn to the hooks of the cylinder needles at a levelabove the dial needles; feeding a pile yarn to the dial needles whilethe hooks of the cylinder needles are above the dial needles; moving thedial needles to draw a loop of pile yarn transversely between pairs ofcylinder needles as the latter are moved toward a cast-0E position;catching the pile yarn in the hooks of the cylinder needles below thebody yarn therein during such movement toward the cast-off position;drawing the body and pile yarn caught in the hooks of the cylinderneedles through previously formed loops around the cylinder needles; andsubsequently casting off the newly formed loops from the cylinderneedles and the pile yarn loops from the dial needles.

5. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a body yarn to the hooks of the cylinder needles at a levelabove the dial needles; feeding a pile yarn to the dial needles whilethe hooks of the cylinder needles are above the dial needles; moving thedial needles to draw an elongated loop of pile yarn transversely betweenpairs of cylinder needles as the latter are moved toward a cast-0Eposition; catching the pile yarn in the hooks of the cylinder needlesbelow the body yarn therein during such movement toward the cast-ofl?position; drawing the body and pile yarn caught in the hooks of thecylinder needles through previously formed loops around the cylinderneedles; and subsequently casting olf the newly formed loops from thecylinder needles and the pile yarn loops from the dial needles.

6. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a 'body yarn to the hooks of the cylinder needles in the knitposition; projecting the dial needles between the cylinder needles inthe knit position at a level below the needle hook; feeding a pile loopyarn to the projected dial needles; retracting the pile needles to drawa loop of pile yarn transversely between pairs of cylinder needles asthe latter are moved toward a cast-01f position; catching the pile yarnin the books of the cylinder needles below the body yarn therein duringsuch movement toward the cast-01f position; drawing the body and pileyarn caught in the hooks of the cylinder needles through previouslyformed loops around the cylinder needles; and subsequently casting olfthe newly formed loops from the cylinder needles and the pile yarn loopsfrom the dial needles.

7. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a "body yarn to the hooks of the cylinder needles in the knitposition; projecting the dial needles between the cylinder needles inthe knit position at a level below the needle hook; feeding a pile loopyarn to the projected dial needles; retracting the dial needles to drawan elongated loop of pile yarn transversely between pairs of cylinderneedles as the latter are moved toward a cast-ofl? position; catchingthe pile yarn in the hooks of the cylinder needles below the body yarntherein during such movement toward the cast oif position; drawing thebody and pile yarn caught in the hooks of the cylinder needles throughpreviously formed loops around the cylinder needles; and subsequentlycasting off the newly formed loops from the cylinder needles and thepile yarn loops from the dial needles.

8. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a stitch yarn to the hooks of the cylinder needles in advance offeeding the pile yarn thereto; substantially simultaneously therewith,feeding a pile yarn to the dial needles, operating between the cylinderneedles, at a level below the hooks of the cylinder needles in the knitposition; drawing pile yarn loops between pairs of cylinder needleshaving the stitch yarn caught therein; subsequently catching the pileyarn in the hooks of the cylinder needles below the body yarn thereinwhile retaining the pile yarn loops in drawn position; drawing thestitch and pile yarn loops through previously formed loops around thecylinder needles; and subsequently casting off the newly formed stitchyarn loops and the retained pile yarn loops.

9. A method of knitting pile fabric utilizing cylinder needlescooperable with movable dial needles operating between the cylinderneedles, said method comprising, in each stitch forming sequence,feeding a stitch yarn to the books of the cylinder needles in advance offeed ing the pile yarn thereto; substantially simultaneously therewith,feeding a pile yarn to the dial needles, operating between the cylinderneedles, at a level below the hooks of the cylinder needles in the knitposition; drawing elongated pile yarn loops between pairs of cylinderneedles having the stitch yarn caught therein; subsequently catching thepile yarnin the hooks of the cylinder needles below the body yarntherein while retaining the pile yarn loops in drawn position; drawingthe stitch and pile yarn loops through previously formed loops aroundthe cylinder needles; and subsequently casting ofi the newly formedstitch yarn loops and the retained pile yarn loops.

References Cited in the file of this patent UNITED STATES PATENTS466,898 Black Jan. 12, 1892 1,777,699 McAdams Oct. 7, 1930 2,133,840Anderson Oct. 18, 1938 2,220,428 Shager Nov. 5, 1940 2,270,719 SmithIan. 20, 1942 2,421,816 Thurston et a1. June 10, 1947 2,796,751 MishconJune 25, 1957

